KTM 1190 RC8 R 2014 Owner's manual

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OWNER'S MANUAL 2014
1190 RC8 R EU/GB
1190 RC8 R FR
1190 RC8 R JP
Art. no. 3213111en
DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle.
Please enter the serial numbers of your vehicle below.
Vehicle identification number/type label ( p. 20) Dealer's stamp
Engine number ( p. 21)
Key number ( p. 20)
The owner's manual contained the latest information for this model at the time of going to print. Minor differences due to developments in
design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these
to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,
deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of delivery.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
DEAR KTM CUSTOMER 2
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÃœV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 3
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ........................................ 8
1.1 Symbols used ...................................................... 8
1.2 Formats used....................................................... 8
2 SAFETY ADVICE.............................................................. 9
2.1 Use definition - intended use ................................ 9
2.2 Safety advice....................................................... 9
2.3 Degrees of risk and symbols................................ 10
2.4 Tampering warning............................................. 10
2.5 Safe operation ................................................... 11
2.6 Protective clothing ............................................. 12
2.7 Work rules......................................................... 12
2.8 Environment...................................................... 12
2.9 Owner's Manual ................................................. 13
3 IMPORTANT NOTES...................................................... 14
3.1 Guarantee, warranty ........................................... 14
3.2 Operating and auxiliary substances...................... 14
3.3 Spare parts, accessories ..................................... 14
3.4 Service ............................................................. 14
3.5 Figures ............................................................. 15
3.6 Customer service................................................ 15
4 VIEW OF VEHICLE ........................................................ 16
4.1 View of vehicle, front left (example) ..................... 16
4.2 View of vehicle, rear right (example) .................... 18
5 SERIAL NUMBERS ....................................................... 20
5.1 Vehicle identification number/type label............... 20
5.2 Key number....................................................... 20
5.3 Engine number .................................................. 21
5.4 Fork part number ............................................... 21
5.5 Shock absorber part number ............................... 22
5.6 Steering damper part number.............................. 22
6 CONTROLS................................................................... 23
6.1 Clutch lever....................................................... 23
6.2 Hand brake lever................................................ 23
6.3 Throttle grip ...................................................... 24
6.4 Horn button....................................................... 24
6.5 Light switch ...................................................... 25
6.6 Headlight flasher switch ..................................... 25
6.7 Turn signal switch.............................................. 26
6.8 Emergency OFF switch ....................................... 26
6.9 Electric starter button......................................... 27
6.10 Ignition/steering lock.......................................... 27
6.11 Combination instrument ..................................... 28
6.11.1 Overview ....................................................... 28
6.11.2 function buttons, handlebar............................ 29
6.11.3 Activation and test......................................... 30
6.11.4 Display ......................................................... 31
6.11.5 Info display ................................................... 32
6.11.6 Indicator lamps ............................................. 33
6.11.7 Immobilizer................................................... 34
6.11.8 notes/warnings............................................... 34
6.11.9 Overview of ROAD mode ................................. 38
6.11.10 Distance menu 1, ODO/Trip 1/Time 1/Avs 1 ..... 39
6.11.11 Distance menu 2, ODO/Trip 2/Time 2/Avs 2 ..... 40
6.11.12 Gear display menu, ODO/Trip 1/Gear................ 41
6.11.13 Fuel and external temperature menu, FUEL...... 43
6.11.14 Mapping menu, ENGINE MAP......................... 44
6.11.15 Next service menu, DISTANCE TO
Next Service.................................................. 45
TABLE OF CONTENTS 4
6.11.16 Overview of RACE mode ................................. 46
6.11.17 Remaining laps menu, LAPSTOGO .................. 47
6.11.18 Maximum lap speed menu, TOPSPEED............ 48
6.11.19 Gear display menu, LastLap/RaceTrip/Gear....... 50
6.11.20 Fuel and external temperature menu, FUEL...... 51
6.11.21 Mapping menu, ENGINE MAP......................... 52
6.11.22 Lap times menu, LAP/BESTLAP/LapTime......... 53
6.11.23 Maximum speed menu, LAP/BESTLAP/
TopSpeed ..................................................... 54
6.11.24 Total distance in Race mode menu,
RACEODO..................................................... 55
6.11.25 Overview of SET‑UP mode .............................. 56
6.11.26 SET‑UP menu ............................................... 58
6.11.27 Mode menu, CHANGE MODE.......................... 59
6.11.28 Time menu, SET CLOCK................................. 60
6.11.29 SETTINGS menu ........................................... 61
6.11.30 Shift warning lamp menu, SHIFT RPMS........... 62
6.11.31 LAP button blank time, LAP BLANK TIME
menu............................................................ 63
6.11.32 Number of laps menu, SET NUM LAPS............ 64
6.11.33 Fuel reserve display menu, TRIP F RESET........ 65
6.11.34 UNITS menu ................................................. 67
6.11.35 Kilometers/miles menu, SET KM/MILES........... 68
6.11.36 Temperature display menu, SET °C/°F ............. 69
6.11.37 Fuel consumption menu (liters),
SET FUEL CONS ........................................... 70
6.11.38 Fuel consumption menu (gallons),
SET GAL US/UK ............................................ 71
6.11.39 Additional functions menu, OPTIONS .............. 72
6.11.40 Quick shifter menu, OPTION QKSHIFT ............ 73
6.11.41 External temperature display menu,
OPTION OUTTEMP ........................................ 74
6.11.42 Tire pressure monitor menu, OPTION TPMS ..... 75
6.11.43 Table of functions.......................................... 76
6.11.44 Table of conditions and menu activation .......... 80
6.11.45 Adjusting the mapping of the engine
electronics ENGINE MAP ............................... 83
6.11.46 Displaying lap times....................................... 84
6.11.47 Displaying maximum speed............................. 85
6.11.48 Setting ROAD or RACE mode .......................... 86
6.11.49 Setting the clock with SET CLOCK .................. 86
6.11.50 Adjusting the shift speed RPM1/2 ................... 87
6.11.51 Setting the blank time of the LAP button
LAP BLANK TIME.......................................... 88
6.11.52 Setting the number of laps SET NUM LAPS ..... 90
6.11.53 Setting the fuel reserve display
TRIP F RESET............................................... 91
6.11.54 Setting the kilometers/miles SET KM/MILES .... 92
6.11.55 Setting the temperature unit SET °C/°F............ 93
6.11.56 Setting the unit of fuel consumption (liters)
SET FUEL CONS ........................................... 94
6.11.57 Unit of fuel consumption (gallons)
SET GAL US/UK ............................................ 95
6.11.58 Switching the external temperature display
on/off ........................................................... 96
6.12 Opening the filler cap......................................... 97
6.13 Closing the filler cap .......................................... 98
6.14 Seat lock........................................................... 98
6.15 Tool set............................................................. 99
6.16 Supporting strap ................................................ 99
TABLE OF CONTENTS 5
6.17 Passenger footrests .......................................... 100
6.18 Shift lever ....................................................... 100
6.19 Foot brake lever ............................................... 101
6.20 Side stand....................................................... 102
6.21 Helmet lock..................................................... 102
7 PREPARING FOR USE................................................. 103
7.1 Advice on first use ........................................... 103
7.2 Running the engine in ...................................... 104
7.3 Loading the vehicle.......................................... 105
8 RIDING INSTRUCTIONS.............................................. 107
8.1 Checks and maintenance measures when
preparing for use.............................................. 107
8.2 Starting........................................................... 108
8.3 Starting off...................................................... 109
8.4 Shifting, riding ................................................ 110
8.5 Braking........................................................... 113
8.6 Stopping, parking............................................. 114
8.7 Transport ........................................................ 115
8.8 Refueling ........................................................ 116
9 SERVICE SCHEDULE .................................................. 118
9.1 Service schedule.............................................. 118
10 TUNING THE CHASSIS ............................................... 121
10.1 Fork/shock absorber ......................................... 121
10.2 Adjusting the compression damping of the
fork ................................................................ 121
10.3 Adjusting the rebound damping of the fork ......... 122
10.4 Adjusting the spring preload of the fork.............. 123
10.5 Compression damping of the shock absorber....... 124
10.6 Adjusting the low-speed compression damping
of the shock absorber ....................................... 125
10.7 Adjusting the high-speed compression damping
of the shock absorber ....................................... 126
10.8 Adjusting the rebound damping of the shock
absorber.......................................................... 127
10.9 Adjusting the spring preload of the shock
absorber x..................................................... 127
10.10 Steering damper .............................................. 129
10.11 Adjusting the steering damper........................... 130
10.12 Vehicle level.................................................... 131
10.13 Adjusting front vehicle level x......................... 132
10.14 Adjusting the vehicle level at the rear ................ 134
10.15 Footrest position .............................................. 135
10.16 Adjusting the footrest position........................... 135
10.17 Adjusting shift lever stub .................................. 138
10.18 Adjusting the foot brake lever stub..................... 139
10.19 Adjusting shift lever ......................................... 139
10.20 Adjusting the foot brake lever............................ 143
10.21 Checking the free travel of the foot brake lever.... 143
10.22 Handlebar height/position ................................. 144
10.23 Adjusting the handlebar height/position ............. 145
10.24 Rear frame position.......................................... 150
10.25 Adjusting the subframe position ........................ 151
11 SERVICE WORK ON THE CHASSIS............................... 156
11.1 Raising the rear of the motorcycle with lifting
gear................................................................ 156
11.2 Removing the rear of motorcycle from the lifting
gear................................................................ 156
11.3 Raising the front of the motorcycle with lifting
gear................................................................ 157
TABLE OF CONTENTS 6
11.4 Taking the motorcycle off of the front wheel
stand .............................................................. 157
11.5 Bleeding fork legs ............................................ 158
11.6 Removing the seat ........................................... 158
11.7 Fitting the seat ................................................ 159
11.8 Mounting the helmet lock on the vehicle ............ 159
11.9 Removing the passenger seat ............................ 160
11.10 Mounting the passenger seat............................. 160
11.11 Checking for chain dirt ..................................... 161
11.12 Cleaning the chain ........................................... 161
11.13 Checking the chain tension............................... 162
11.14 Adjusting the chain tension............................... 163
11.15 Checking the chain, rear sprocket and engine
sprocket.......................................................... 165
11.16 Adjusting basic position of clutch lever .............. 168
11.17 Checking fluid level of hydraulic clutch.............. 168
11.18 Correcting fluid level of hydraulic clutch ............ 169
12 BRAKE SYSTEM ......................................................... 170
12.1 Adjusting the basic position of the hand brake
lever ............................................................... 170
12.2 Checking the front brake discs .......................... 170
12.3 Checking the rear brake disc ............................. 171
12.4 Checking the front brake fluid level ................... 172
12.5 Adding brake fluid of front brake x.................. 172
12.6 Checking the front brake linings ........................ 174
12.7 Checking the rear brake fluid level..................... 175
12.8 Adding rear brake fluid x................................ 176
12.9 Checking the rear brake linings ......................... 178
13 WHEELS, TIRES ......................................................... 179
13.1 Removing the front wheel x ............................ 179
13.2 Installing the front wheel x............................. 180
13.3 Removing the rear wheel x.............................. 183
13.4 Installing the rear wheel x .............................. 184
13.5 Checking rear hub cush drive x....................... 186
13.6 Checking the tire condition ............................... 187
13.7 Checking the tire pressure ................................ 189
14 ELECTRICAL SYSTEM ................................................. 191
14.1 Removing the battery x .................................. 191
14.2 Installing the battery x................................... 193
14.3 Recharging the battery x ................................ 194
14.4 Changing the main fuse.................................... 197
14.5 Changing the fuses of individual power
consumers....................................................... 199
14.6 Changing the low beam bulb ............................. 201
14.7 Changing the high beam bulb............................ 204
14.8 Checking the headlight setting .......................... 207
14.9 Adjusting the headlight range............................ 207
14.10 Activating/deactivating ignition key.................... 208
15 COOLING SYSTEM ...................................................... 212
15.1 Cooling system ................................................ 212
15.2 Checking the coolant level ................................ 212
15.3 Filling cooling system compensating tank........... 213
16 TUNING THE ENGINE................................................. 215
16.1 Checking the play in the throttle cable ............... 215
16.2 Adjusting the play in the throttle cable x.......... 216
17 SERVICE WORK ON THE ENGINE ................................ 217
17.1 Checking the engine oil level............................. 217
TABLE OF CONTENTS 7
17.2 Changing engine oil and filter, cleaning oil
screen x........................................................ 218
17.3 Draining engine oil, cleaning oil screens x........ 218
17.4 Removing the oil filter x................................. 221
17.5 Installing the oil filter x.................................. 223
17.6 Filling up with engine oil x ............................. 223
17.7 Adding engine oil............................................. 225
18 CLEANING, CARE ....................................................... 227
18.1 Cleaning motorcycle......................................... 227
18.2 Checks and maintenance steps for winter
operation......................................................... 229
19 STORAGE................................................................... 230
19.1 Storage ........................................................... 230
19.2 Preparing for use after storage........................... 231
20 TROUBLESHOOTING .................................................. 232
21 IMMOBILIZER BLINK CODE ........................................ 235
22 ENGINE CONTROL BLINK CODE.................................. 237
23 TECHNICAL DATA....................................................... 243
23.1 Engine ............................................................ 243
23.2 Engine tightening torques ................................. 244
23.3 Capacities ....................................................... 247
23.3.1 Engine oil ................................................... 247
23.3.2 Coolant....................................................... 248
23.3.3 Fuel ........................................................... 248
23.4 Chassis ........................................................... 248
23.5 Electrical system.............................................. 250
23.6 Tires............................................................... 250
23.7 Fork................................................................ 251
23.8 Shock absorber................................................ 252
23.9 Chassis tightening torques ................................ 253
24 SUBSTANCES ............................................................ 257
25 AUXILIARY SUBSTANCES ........................................... 261
26 STANDARDS .............................................................. 263
INDEX ............................................................................... 264
1 MEANS OF REPRESENTATION 8
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally
cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name
®
Identifies a protected name.
Brandâ„¢ Identifies a brand available on the open market.
2 SAFETY ADVICE 9
2.1 Use definition - intended use
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation and also for use on race
courses, but not for offroad use.
Info
The motorcycle is only authorized for operation on public roads in the homologated version.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instruc-
tions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they
are missing, you or others may not recognize dangers and may therefore be injured.
2 SAFETY ADVICE 10
2.3 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or
element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur-
chaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
2 SAFETY ADVICE 11
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufac-
turer.
2.5 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally
compatible manner.
The vehicle should only be used by trained persons. An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2 SAFETY ADVICE 12
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear
protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parenthe-
ses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
In some instances, a thread locker (e.g. Loctite
®
) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle
sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that per-
tain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2 SAFETY ADVICE 13
2.9 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains use-
ful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the
vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
3 IMPORTANT NOTES 14
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered
for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed
by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to
advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis
is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage
and breakage of components.
3 IMPORTANT NOTES 15
Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of
components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace
parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassem-
ble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
4 VIEW OF VEHICLE 16
4.1 View of vehicle, front left (example)
B01301-10
4 VIEW OF VEHICLE 17
1 Clutch lever ( p. 23)
2 Light switch ( p. 25)
2 Headlight flasher switch ( p. 25)
2 Turn signal switch ( p. 26)
2 Horn button ( p. 24)
3 Filler cap
4 Tool set ( p. 99)
5 Seat lock ( p. 98)
6 Oil dipstick
7 Side stand ( p. 102)
8 Shift lever ( p. 100)
9 Helmet lock ( p. 102)
10 Passenger footrests ( p. 100)
4 VIEW OF VEHICLE 18
4.2 View of vehicle, rear right (example)
B01302-10
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